Method of manufacturing a battery

ABSTRACT

A method for manufacturing a battery is provided and including preparing the battery comprising an exterior material, the exterior material comprising a sealed portion; housing at least the sealed portion of the battery in a space portion of a chamber; providing the space portion into a pressurized state; and opening a partial portion of the battery other than the sealed portion to an atmosphere.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/249,027 filed on Apr. 9, 2014 which claims priority toJapanese Priority Patent Application JP 2013-088917 filed in the JapanPatent Office on Apr. 19, 2013, the entire content of which is herebyincorporated by reference.

BACKGROUND

The present disclosure relates to an inspection apparatus, an inspectionmethod, and a battery-inspecting chamber for inspecting an inspectiontarget including a sealed portion.

In the related art, there are widely used batteries each including abattery element covered with an exterior material such as a laminatefilm. In a manufacture process of such a battery, a battery-sealed stateis inspected for checking whether or not a completed battery has asealing failure.

As an inspection apparatus for inspecting the battery-sealed state, forexample, there has been proposed one that houses a battery in ahermetically sealed container pressurized or depressurized, measures achange in pressure from a state before the pressurization ordepressurization, and determines the presence of a leakage if a largechange in pressure above a predetermined threshold value is measured(e.g., see Japanese Patent No. 3983479). In recent years, it isdesirable to provide an inspection apparatus capable of inspecting thebattery-sealed state in a short time.

SUMMARY

Therefore, it is desirable to provide an inspection apparatus, aninspection method, and a battery-inspecting chamber, by which abattery-sealed state can be inspected in a short time.

According to a first embodiment of the present disclosure, there isprovided an inspection apparatus including: a chamber including a spaceportion configured to house at least a sealed portion of a battery, andan opening portion configured to open a partial portion of the batteryother than the sealed portion to an atmosphere; and a pressurizerconfigured to put the space portion into a pressurized state.

According to a second embodiment of the present disclosure, there isprovided an inspection method including: housing at least a sealedportion of a battery in a space portion of a chamber; and putting thespace portion into a pressurized state and opening the partial portionof the battery other than the sealed portion to an atmosphere.

According to a third embodiment of the present disclosure, there isprovided a battery-inspecting chamber including: a space portionconfigured to house at least a sealed portion of a battery; and anopening portion configured to open a partial portion of the batteryother than the sealed portion to an atmosphere.

According to a fourth embodiment of the present disclosure, there isprovided an inspection apparatus including: a chamber including a spaceportion configured to house at least a sealed portion of an inspectiontarget, and an opening portion configured to open a partial portion ofthe inspection target other than the sealed portion to an atmosphere;and a pressurizer configured to put the space portion into a pressurizedstate.

In the first to third embodiments, at least the sealed portion of thebattery is housed in the space portion of the chamber. The space portionis put into the pressurized state and the partial portion of the batteryother than the sealed portion is opened to the atmosphere. Therefore, ifthe battery has a sealing failure, the gas pressure within the batteryis higher than the external atmospheric pressure in the opening portion,and swelling of the battery is generated in the opening portion. By aworker or the like visually checking the swelling or by a measurementapparatus such as a position sensor measuring the swelling, the presenceor the absence of the sealing failure of the battery can be checked.Further, a pressurized atmosphere is used as the atmosphere in thechamber, and hence it is possible to reduce an inspection time incomparison with an inspection method using a vacuum atmosphere as theatmosphere in the chamber.

As described above, according to the embodiments of the presentdisclosure, it is possible to inspect the battery-sealed state in ashort time.

These and other objects, features and advantages of the presentdisclosure will become more apparent in light of the following detaileddescription of best mode embodiments thereof, as illustrated in theaccompanying drawings.

Additional features and advantages are described herein, and will beapparent from the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a perspective view showing an exemplary outer appearance as abattery serving as an inspection target is viewed from a side of onemain surface; and FIG. 1B is a perspective view showing an exemplaryouter appearance as the battery serving as the inspection target isviewed from a side of the other main surface;

FIG. 2 is an exploded perspective view showing an exemplaryconfiguration of the battery serving as the inspection target;

FIG. 3 is a schematic view showing an exemplary configuration of aninspection apparatus according to a first embodiment of the presentdisclosure;

FIG. 4A is a plane view showing an exemplary outer appearance of achamber according to the first embodiment of the present disclosure; andFIG. 4B is a cross-sectional view taken along the line A-A of FIG. 4A;

FIG. 5 is a flowchart for explaining an exemplary inspection methodaccording to the first embodiment of the present disclosure;

FIG. 6A is a plane view showing an exemplary outer appearance of thebattery after an inspection, which has a sealing failure, a pin hole, orthe like in an exterior material; and FIG. 6B is a side view showing theexemplary outer appearance of the battery after the inspection, whichhas the sealing failure, the pin hole, or the like in the exteriormaterial;

FIG. 7A is a plane view showing an exemplary outer appearance of thebattery after an inspection, which does not have a sealing failure, apin hole, or the like in an exterior material; and FIG. 7B is a sideview showing the exemplary outer appearance of the battery after theinspection, which does not have the sealing failure, the pin hole, orthe like in the exterior material;

FIGS. 8A and 8B are plane views showing a modified example of thechamber according to the first embodiment of the present disclosure;

FIG. 9 is a schematic view showing an exemplary configuration of aninspection apparatus according to a second embodiment of the presentdisclosure;

FIG. 10A is a cross-sectional view showing exemplary displacement sensorand chamber of the inspection apparatus shown in FIG. 9; and FIG. 10B isa cross-sectional view showing a modified example of the inspectionapparatus according to the second embodiment of the present disclosure;

FIG. 11 is a flowchart for explaining an exemplary inspection methodaccording to the second embodiment of the present disclosure; and

FIG. 12A is a cross-sectional view showing an exemplary configuration ofa chamber according to a third embodiment of the present disclosure; andFIG. 12B is a cross-sectional view showing a modified example of thechamber according to the third embodiment of the present disclosure.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present disclosure will be describedwith reference to the drawings in the following order. Note that thesame or corresponding portions are denoted by the same reference symbolsin all the figures relating to the following embodiments.

1 First Embodiment (First Example of Inspection Apparatus)

-   -   1.1 Configuration of Battery    -   1.2 Configuration of Inspection Apparatus    -   1.3 Configuration of Chamber    -   1.4 Inspection Method    -   1.5 Effect    -   1.6 Modified Example

2 Second Embodiment (Second Example of Inspection Apparatus)

-   -   2.1 Configuration of Inspection Apparatus    -   2.2 Inspection Method    -   2.3 Effect    -   2.4 Modified Example

3 Third Embodiment (Example of Chamber)

-   -   3.1 Configuration of Chamber    -   3.2 Inspection Method    -   3.3 Effect    -   3.4 Modified Example

1. First Embodiment 1.1 Configuration of Battery

First, referring to FIGS. 1A, 1B, and 2, a configuration of a battery 1serving as the inspection target will be described. The battery 1 is aflat battery including two main surfaces S1 and S2. The battery 1 ismanufactured by covering a battery element 11 provided with a positiveelectrode lead 13 and a negative electrode lead 14 with an exteriormaterial 12. Thus, reductions in size, weight, and thickness can beachieved. Hereinafter, an end surface side of the battery element 11,from which the positive electrode lead 13 and the negative electrodelead 14 are pulled out, will be referred to as a top side. Further, anend surface side opposite to the former end surface side will bereferred to as a bottom side. In addition, a side of side portionsbetween both end portions on the top side and the bottom side will bereferred to as a middle side.

Each of the positive electrode lead 13 and the negative electrode lead14 extends from an inside to an outside of the exterior material 12, andis pulled out in the same direction, for example. The positive electrodelead 13 and the negative electrode lead 14 are, for example, made of ametal material such as an aluminum, a copper, a nickel, and a stainlesssteel and formed in a thin-plate shape or a net-like shape.

The battery 1 includes a sealed portion(s) in all the side portions orsome of the side portions. Note that FIGS. 1A, 1B, and 2 show an examplein which side portions on the top side and the middle side out of theside portions of the battery 1 include the sealed portions. The sealedportions are formed in the following manner. Specifically, for example,one rectangular exterior material 12 is folded back at its center andbonded by thermal fusion or the like while sandwiching the batteryelement 11 and overlapping the folded-back side portions with eachother. Alternatively, the battery 1 is sandwiched between tworectangular exterior materials 12 and bonded by thermal fusion whileoverlapping the side portions with each other.

The exterior material 12 is, for example, a soft laminate film. Theexterior material 12 has a configuration in which, for example, athermal fusion resin layer, a metal layer, and a surface protectionlayer are sequentially stacked. Note that a surface on a side of thethermal fusion resin layer is a surface on a side on which the batteryelement 11 is housed. Examples of the thermal fusion resin layer includea polymer material such as a polypropylene (PP) and a polyethylene (PE).Examples of the material of the metal layer include a metal materialsuch as an aluminum (Al) or an alloy thereof. Examples of the materialof the surface protection layer include a polymer material such a nylon(Ny). Specifically, for example, the exterior material 12 is formed of,for example, a rectangular aluminum laminate film in which a nylon film,an aluminum film, and a polyethylene film are bonded in the statedorder. For example, the exterior material 12 is provided such that apolyethylene film side and the battery element 11 are opposed to eachother and the respective side portions are bonded to each other byfusion or with an adhesive. Adhesive films 15 for enhancing sealingproperties are inserted between the exterior material 12 and thepositive electrode lead 13 and negative electrode lead 14. Each of theadhesive films 15 is formed of a material having an adhesion to thepositive electrode lead 13 and the negative electrode lead 14, forexample, a polyolefin resin such as a polyethylene, a polypropylene, amodified polyethylene, and a modified polypropylene.

Note that a laminate film having another configuration, a polymer filmof a polypropylene or the like, a metal film, or the like may be used asthe exterior material 12 instead of the laminate film having theabove-mentioned structure.

Although the configuration of the battery element 11 is not particularlylimited, the examples of the configuration of the battery element 11 mayinclude a wiring electrode structure and a stack electrode structure. Asan electrolyte of the battery element 11, for example, an electrolyticsolution, a gel-like electrolyte, or a solid electrolyte is used.

1.2 Configuration of Inspection Apparatus

Next, referring to FIG. 3, a configuration of the inspection apparatusthat inspects a sealed state of the battery 1 having the above-mentionedconfiguration will be described. The inspection apparatus includes apressurizer 21, a pressure controller 22, a chamber 23, a controlapparatus 24, and a display apparatus 25. The pressurizer 21 and thepressure controller 22 are connected to each other via a communicationpipe 26. The pressure controller 22 and the chamber 23 are connected toeach other via a communication pipe 27.

The pressurizer 21 puts the chamber 23 into a pressurized state. Thepressurizer 21 is, for example, a compressor, and compresses gas such asthe air and supplies the gas into the chamber 23 via the pressurecontroller 22 as compressed gas.

The pressure controller 22 includes a regulator. The pressure controller22 adjusts a pressure of the compressed gas supplied from thepressurizer 21 into a predetermined pressure by this regulator andsupplies the adjusted compressed gas into the chamber 23. The pressurecontroller 22 may further include an air filter depending on needs. Thepressure controller 22 may prevent moisture and foreign particles in thecompressed gas from entering the pressure controller 22 by the airfilter. The pressure controller 22 may further include a pressure gaugedepending on needs. The pressure controller 22 may check an adjustedpressure in the pressure controller 22 by the pressure gauge.

The compressed gas is supplied from the pressurizer 21 into the chamber23 via the pressure controller 22. The chamber 23 houses at least thesealed portion of the battery 1 and causes a partial portion of each ofthe main surfaces S1 and S2 of the battery 1 to be exposed from thechamber 23. Thus, in the chamber 23 under the pressurized state, thepartial portion of each of the main surfaces S1 and S2 of the battery 1is opened to the atmosphere.

The control apparatus 24 controls the pressurizer 21 and the pressurecontroller 22. Specifically, the control apparatus 24 outputs a controlsignal to the pressurizer 21 and controls a gas-compressing operation ofthe pressurizer 21. Further, the control apparatus 24 outputs a controlsignal to the pressure controller 22 and adjusts the pressure of thecompressed gas supplied from the pressurizer 21 to the chamber 23 into apredetermined pressure. With this, the chamber 23 is controlled to havethe predetermined pressure. Further, the control apparatus 24 displays,based on a supply signal supplied from the pressure controller 22,information on a control state or the like of the pressure controller 22on the display apparatus 25.

The display apparatus 25 is one of examples of the output unit, anddisplays, based on a signal supplied from the control apparatus 24,information on a control state or the like of the pressurizer 21 and thepressure controller 22. As the display apparatus 25, for example, aliquid-crystal display or an electro luminescence (EL) display may beused.

1.3 Configuration of Chamber

Next, referring to FIGS. 4A and 4B, a configuration of theabove-mentioned chamber 23 will be described in detail. The chamber 23serving as a battery-inspecting chamber has a disk shape, and includes aspace portion 23 a for housing at least the sealed portion of thebattery 1 therein. A lower surface and an upper surface of the chamber23 are provided with hole portions 32 and 42. In a state in which thebattery 1 is housed at a predetermined position within the chamber 23,the partial portions of the main surfaces S1 and S2 of the battery 1(e.g., center portions of the main surfaces S1 and S2) are exposed fromthe chamber 23 through the hole portions 32 and 42. With this, in thepressurized state of the space portion 23 a, the partial portions of themain surfaces S1 and S2 of the battery 1 are opened to the atmospherethrough the hole portions 32 and 42. Note that, in this example, thepartial portions of the main surfaces S1 and S2 of the battery 1 arepartial portions of the battery 1 other than the sealed portion.Although the shape of the hole portions 32 and 42 is not particularlylimited, examples of the shape of the hole portions 32 and 42 mayinclude a circular shape, an elliptical shape, and a polygonal shapesuch as a rectangular shape and a hexagonal shape. Here, the shape ofthe hole portions 32 and 42 means a shape as the hole portions 32 and 42are viewed in a direction perpendicular to the lower surface and theupper surface.

The chamber 23 includes a chamber lower portion 31 and a chamber upperportion 41 that are configured to be separable from each other. Bycombining the chamber lower portion 31 and the chamber upper portion 41,the space portion 23 a for housing the battery 1 is formed. The holeportions 42 and 32 are arranged in centers of the chamber upper portion41 and the chamber lower portion 31, respectively. Note that thearrangement of the hole portions 32 and 42 is not limited to thisexample, and the hole portions 32 and 42 do not need to overlap witheach other, but may be offset with respect to each other in a thicknessdirection of the chamber 23 in a state in which the chamber lowerportion 31 and the chamber upper portion 41 are combined.

In rims of the hole portions 32 and 42 on a side of the space portion 23a, the packings 33 and 43 having a shape conforming with the holeportions 32 and 42 are provided, respectively. In a state in which thebattery 1 is housed in the space portion 23 a, the packing 33 isprovided between the rim of the hole portion 32 on the side of the spaceportion 23 a and the main surface S2 of the battery 1 and the packing 43is provided between the rim of the hole portion 42 on the side of thespace portion 23 a and the main surface S1 of the battery 1. The spaceportion 23 a is closed by the packings 33 and 43 and thus the compressedgas is prevented from leaking from the space portion 23 a to an outside.The material of the packings 33 and 43 only need to be capable ofpreventing the leakage of the compressed gas and is not particularlylimited. Examples of the material of the packings 33 and 43 may includea rubber-based material such as a nitrile rubber, a fluoro-rubber, aurethane rubber, a silicone rubber, an acrylic rubber, anethylene-propylene rubber, and a styrene-butadiene rubber.

The chamber lower portion 31 is a housing portion for housing thebattery 1, and includes, for example, a main-body portion 31 a having acircular shape and a peripheral wall portion 31 b provided in a rim ofthe main-body portion 31 a. In a center portion of the main-body portion31 a, the hole portion 32 passing from one main surface to the othermain surface is provided. Via the hole portion 32, the partial portionof the main surface S2 of the battery 1 housed in the chamber 23 isexposed.

The chamber upper portion 41 is, for example, a lid portion having acircular shape or the like that is disposed on the chamber lower portion31. In a center portion of the chamber upper portion 41, the holeportion 42 passing from one main surface to the other main surface isprovided. The partial portion of the main surface S1 of the battery 1housed in the chamber 23 is exposed through the hole portion 42.Further, a supply port 45 is provided at a position displaced from thecenter of the chamber upper portion 41. The compressed gas is suppliedfrom the pressurizer 21 into the chamber 23 via the supply port 45. Thesupply port 45 is provided with a connection portion 46. Thecommunication pipe 27 is connected to the supply port 45 via theconnection portion 46.

The chamber upper portion 41 may include a packing holder 44 for holdingthe packing 43. Further, the packing holder 44 may be configured to bemovable in a direction closer to or away from the main surface S1 of thebattery 1 housed at a predetermined position within the space portion 23a. In a case where such a configuration is adopted, a close contactproperty between an edge of the packing 43 and the main surface S1 ofthe battery can be enhanced by the movement of the packing holder 44.The packing holder 44 only needs to be configured to be capable ofholding the packing 43, and the shape thereof is not particularlylimited. Although the configuration in which only the chamber upperportion 41 includes the packing holder 44 is described as an exampleherein, the chamber lower portion 31 may also include a packing holder.

Within the chamber 23, support sections 36 and 37 for supporting thebattery 1 are provided. The support section 36 supports a portion on thetop side of the battery 1. The support section 37 supports a portion ofon the bottom side of the battery 1. By supporting the battery 1 in thismanner, when the compressed gas is supplied into the space portion 23 a,it is possible to prevent the battery 1 from being displaced due to thecompressed gas. Further, due to the support of the battery 1, a spacecan be formed between an inner side surface of the main-body portion 31a and the main surfaces S1 and S2 of the battery 1. By forming the spacein this manner, the compressed gas can also flow to the main surfaces S1and S2 of the battery 1, and hence a pin hole of the main surfaces S1and S2 of the battery 1 can be also inspected.

The support section 36 includes supporting members 36 a and 36 b and aposition adjuster 36 c. The supporting member 36 a is provided in aninner side surface of the main-body portion 31 a of the chamber lowerportion 31. A portion on the top side of the main surface S2 of thebattery 1 is disposed on the supporting member 36 a. The supportingmember 36 b is connected to the position adjuster 36 c. A position ofthe supporting member 36 b is adjusted by the position adjuster 36 c.The portion on the top side of the main surface S2 of the battery 1 isdisposed on the supporting member 36 a and a position of the supportingmember 36 b is adjusted by the position adjuster 36 c. Therefore, theportion on the top side of the battery 1 is sandwiched and supported bythe supporting members 36 a and 36 b.

The support section 37 includes supporting members 37 a and 37 b and aposition adjuster 37 c. The supporting member 37 a is provided in aninner side surface of the main-body portion 31 a of the chamber lowerportion 31. A portion on the bottom side of the main surface S2 of thebattery 1 is disposed on the supporting member 37 a. The supportingmember 37 b is connected to the position adjuster 37 c and a position ofthe supporting member 37 b is adjusted by the position adjuster 37 c.The portion on the bottom side of the main surface S2 of the battery 1is disposed on the supporting member 37 a and a position of thesupporting member 37 b is adjusted by the position adjuster 37 c. Inthis manner, the portion on the bottom side of the battery 1 issandwiched and supported by the supporting members 37 a and 37 b.

The supporting members 36 a and 37 a may be fixed on the inner sidesurface of the main-body portion 31 a of the chamber lower portion 31 orthe supporting members 37 a and 37 a may be a partial portion of thechamber lower portion 31.

1.4 Inspection Method

Next, referring to FIG. 5, an inspection method for the battery usingthe inspection apparatus having the above-mentioned configuration willbe described. First, in S11, the battery 1 serving as the inspectiontarget is carried in the chamber lower portion 31. The portion on thetop side of the battery 1 is sandwiched and supported by the supportingmembers 36 a and 36 b and the portion on the bottom side of the battery1 is sandwiched and supported by the supporting members 37 a and 37 b.Subsequently, in Step S12, the chamber upper portion 41 is lowered andthe rim of the chamber upper portion 41 is disposed on the peripheralwall portion 31 b of the chamber lower portion 31. An upper end of theperipheral wall portion 31 b of the chamber lower portion 31 and the rimof the chamber upper portion 41 are held in close contact with eachother. With this, the space portion 23 a is formed in the chamber 23,and the space portion 23 a houses at least the sealed portion of thebattery 1 while the partial portions of the main surfaces S1 and S2 ofthe battery 1 are exposed through the hole portions 42 and 32,respectively.

Next, in Step S13, the chamber 23 is locked. Subsequently, in Step S14,the compressed gas such as the compressed air is supplied to the spaceportion 23 a of the chamber 23 and the space portion 23 a is put into acompressed state. At this time, the compressed atmosphere of the spaceportion 23 a is set to, for example, approximately 0.3 MPa to 0.5 MPa.

The space portion 23 a is put into the compressed state in this manner,and hence the portion of the battery 1 that is situated in the spaceportion 23 a is compressed due to the compressed gas while the portionsthat is exposed through the hole portions 32 and 42 are opened to theatmosphere. Thus, if a portion of the exterior material 12 that issituated in the space portion 23 a has a sealing failure, a pin hole, orthe like, the compressed gas enters the battery through that portion andthe exterior material 12 in the portions opened to the atmospherethrough the hole portions 32 and 42 is swollen with the result that aswelling deformation 12 a is generated (see FIGS. 6A and 6B). Theswelling deformation 12 a is a plastic deformation, and hence kept alsoafter the chamber 23 is opened to the atmosphere. On the other hand, ifthe portion of the exterior material 12 that is situated in the spaceportion 23 a does not have a sealing failure, a pin hole, or the like,the compressed gas does not enter the battery through that portion, andhence the exterior material 12 in the portions opened to the atmospherethrough the hole portions 32 and 42 does not change before and after thepressurization (see FIGS. 7A and 7B).

Next, in Step S15, the chamber 23 is opened to the atmosphere.Subsequently, in Step S16, the lock of the chamber 23 is released.Subsequently, in Step S17, after the chamber upper portion 41 is raised,the support of the portion on the top side of the battery 1 by thesupporting members 36 a and 36 b is released and the support of theportion on the bottom side of the battery 1 by the supporting members 37a and 37 b is released. Subsequently, in Step S18, the battery 1 iscarried out of the chamber lower portion 31. Subsequently, in Step S19,the main surfaces S1 and S2 of the battery 1 are visually observed. Ifthe swelling deformation 12 a is observed in the main surfaces S1 and S2in the visual observation (see FIGS. 6A and 6B), it can be determinedthat the battery 1 has a sealing failure, a pin hole, or the like. Onthe other hand, if the swelling deformation 12 a is not observed in themain surfaces S1 and S2 in the visual observation (see FIGS. 7A and 7B),it can be determined that the battery 1 does not have a sealing failure,a pin hole, or the like. In the above-mentioned manner, the inspectionof the battery 1 is completed.

Note that the operations in S11 to S18 may be performed under anautomatic control of the control apparatus 24. In this case, theoperation of carrying in and out the battery 1 only needs to beperformed using a carry-in arm and a carry-out arm, or the like.

1.5 Effect

In the inspection apparatus according to the first embodiment, thechamber 23 includes the space portion 23 a for housing at least thesealed portion out of the entire battery 1, and the hole portions 32 and42 for causing the partial portion of the battery 1 other than thesealed portion (the partial portions of the main surfaces S1 and S2 ofthe battery 1) to be exposed. Thus, when the compressed gas is suppliedto the space portion 23 a of the chamber 23, the sealed portion or thelike housed in the space portion 23 a is compressed while the partialportion of the battery 1 other than the sealed portion is kept opened tothe atmosphere through the hole portions 32 and 42. With this, if theexterior material 12 has the sealing failure or the pin hole and thecompressed gas enters the battery through that portion, the gas pressurewithin the exterior material 12 is higher than the external atmosphericpressure at positions of the hole portions 32 and 42. Therefore, at thepositions of the hole portions 32 and 42, the swelling deformation 12 ais generated in the exterior material 12. By a worker or the likevisually checking the swelling deformation 12 a, it is possible todetermine that the sealing failure or the pin hole is generated in theexterior material 12 of the battery 1 serving as the inspection target.

In a method of inspecting the sealed state of the battery 1 using avacuum state (hereinafter, referred to as “vacuum-type inspectionmethod”), if the exterior material 12 does not have the sealing failureor the pin hole and the battery 1 is a good product, the exteriormaterial 12 of the battery 1 swells. The battery 1 whose the exteriormaterial 12 swells in this manner is a good product, and hence theexterior material 12 needs to be returned to an original state afterbeing opened to the atmosphere. Therefore, the swelling deformation ofthe exterior material 12 needs to be an elastic deformation. On theother hand, if the exterior material 12 has the sealing failure or thepin hole, the exterior material 12 of the battery 1 rarely changes. Inthe vacuum-type inspection method, by visually observing a difference instate or the like, the sealed state of the battery 1 can be checked.However, in this vacuum-type inspection method, the swelling deformationof the exterior material 12 is the elastic deformation, and hence thepresence and absence of the sealing failure or the pin hole of thebattery 1 can be checked only in the state in which the vacuum state iskept. In contrast, in the inspection according to the first embodiment,the swelling deformation 12 a of the exterior material 12 is the elasticdeformation, and hence the swelling deformation 12 a is kept also afterbeing opened to the atmosphere. Thus, the check of the swellingdeformation 12 a does not necessarily needs to be performed in thepressurized state and may also be performed after being opened to theatmosphere. Thus, in the inspection method according to the firstembodiment, it is possible to easily check the presence and the absenceof the sealing failure or the pin hole of the battery 1 in comparisonwith the vacuum-type inspection method.

1.6 Modified Example

Although the chamber 23 has a disk shape in the first embodimentdescribed above, the shape of the chamber 23 is not limited thereto. Forexample, as shown in FIG. 8A, the chamber 23 may have a cubic shape.Further, the chamber 23 may further include a positioning portion 38 forpositioning the battery 1 in the space portion 23 a.

Further, although the chamber 23 houses the single battery 1 in thefirst embodiment described above, the chamber 23 may house a pluralityof batteries 1 as shown in FIG. 8B. In this case, pairs of hole portions32 and 42 corresponding to the number of the battery 1 that can behoused are provided and the partial portions of the main surfaces S1 andS2 of the battery 1 are exposed from the chamber 23 through the holeportions 32 and 42.

Further, although the inspection apparatus includes the single chamber23 in the first embodiment described above, the inspection apparatus mayinclude a plurality of chambers 23. In this case, the chamber 23 may beconfigured to house a plurality of batteries 1 as described above.

Further, although the chamber lower portion 31 and the chamber upperportion 41 include the hole portions 32 and 42, respectively in thefirst embodiment described above, the configuration of the chamber 23 isnot limited thereto. For example, a hole portion may be provided in atleast one of the chamber lower portion 31 and the chamber upper portion41.

Further, although the battery 1 is kept in the pressurized state onlyone time in the first embodiment described above, the battery 1 may bekept in the pressurized state two times by changing the position atwhich the surface of the battery 1 is exposed through the hole portions32 and 42. Specifically, by changing the position at which the surfaceof the battery 1 is exposed through the hole portions 32 and 42, theoperations in Steps S11 to S18 shown in FIG. 5 may be repeated twotimes. With this, even if the pin hole or the like is present at aposition exposed through the hole portions 32 and 42 in a firstpressurized state, the swelling deformation 12 a is not generated in thebattery surface, and the presence of the pin hole or the like cannot bechecked, the swelling deformation 12 a is generated in the batterysurface in a second pressurized state, and hence the presence of the pinhole or the like can be checked. Thus, a detection accuracy of the pinhole or the like can be enhanced.

Further, in the first embodiment described above, the inspectionapparatus may further include an exhaust portion such as a vacuum pump.The exhaust portion may put the chamber 23 into a vacuum state and theninto the pressurized state. By doing so, if the sealed portion of thebattery 1 has an insufficient sealed point, the insufficient sealedpoint can be opened due to the vacuum state. Therefore, in thepressurized state, the compressed gas can flow into the battery throughthe opened sealed point. Thus, it is also possible to check theinsufficient sealed point.

2. Second Embodiment 2.1 Configuration of Inspection Apparatus

As shown in FIG. 9, an inspection apparatus according to the secondembodiment of the present disclosure is different from the inspectionapparatus according to the first embodiment in that the former furtherincludes a displacement sensor (measurement unit) 51. The displacementsensor 51 is provided in vicinity of the hole portion 42 of the chamber23 as shown in FIG. 10A. The displacement sensor 51 measures an amountof displacement of the surface of the battery 1 upon pressurization ofthe chamber 23 through the hole portion 42. As the displacement sensor51, for example, either one of displacement sensors of a contact typeand a non-contact type may be used. Note that FIGS. 9 and 10 show anexample in which an optical sensor such as a laser focus sensor is used.The displacement sensor 51 is controlled based on a control signal fromthe control apparatus 24. Further, upon pressurization of the chamber23, the displacement sensor 51 provides the measured amount ofdisplacement to the control apparatus 24. The control apparatus 24determines, based on the amount of displacement provided from thedisplacement sensor 51, whether or not the battery 1 serving as theinspection target has the sealing failure, and displays a result thereofon the display apparatus 25 as visual information.

The inspection apparatus may further include a lamp 28 and the workermay be informed of the inspection result as the visual information byflashing of the lamp 28 or the like. Examples of the lamp 28 include alight-emitting element such as a light bulb and an LED (Light EmittingDiode). Further, the inspection apparatus may include an audio outputsection 29 such as a speaker and the worker may be informed of theinspection result as audio information such as alarm sound by the audiooutput section 29.

2.2 Inspection Method

Next, referring to FIG. 11, an inspection method for the battery usingthe inspection apparatus having the above-mentioned configuration willbe described. This inspection method is different from the inspectionmethod according to the first embodiment in that the inspectionapparatus according to the second embodiment further performs thefollowing operations between Steps S14 and S15 shown in FIG. 5.

First, in Step S21, the displacement sensor 51 measures the amount ofdisplacement of a portion of the main surface 51 of the battery 1, whichis exposed through the hole portion 32, and provides the measured amountof displacement to the control apparatus 24. Subsequently, in Step S22,the control apparatus 24 determines, based on the amount of displacementprovided from the displacement sensor 51, whether or not the amount ofdisplacement is above a defined value. The defined value of the amountof displacement is favorably selected considering the material or thelike of the exterior material 12. For example, the defined value is setto be about several tens of microns.

If it is determined in step 22 that the amount of displacement is abovethe defined value, the control apparatus 24 displays, in Step S23,information indicating that the battery 1 serving as the inspectiontarget is a defective product on the display apparatus 25, to therebyalarm the worker. After that, the display apparatus 25 performs theoperation of Step S15 shown in FIG. 5. Otherwise, if it is determined inStep 22 that the amount of displacement is not above the defined value,the control apparatus 24 displays, in Step S24, information indicatingthat the battery 1 serving as the inspection target is a non-defectiveproduct on the display apparatus 25. After that, the operation of StepS15 shown in FIG. 5 is performed.

2.3 Effect

In the inspection apparatus according to the second embodiment, thecontrol apparatus 24 determines, based on the amount of displacementprovided from the displacement sensor 51, whether or not the battery 1serving as the inspection target is a non-defective product. Therefore,in comparison with the visual observation, the determination as towhether or not the battery 1 is a non-defective product can be moreaccurately made.

Further, a time necessary to change inspection atmosphere intopressurized atmosphere can be shorter than a time necessary to changethe inspection atmosphere into vacuum atmosphere. Therefore, theinspection time can be reduced in comparison with the vacuum-typeinspection method.

2.4 Modified Example

Although the inspection apparatus includes the displacement sensor 51that measures the amount of displacement of the main surface S1 of thebattery 1 through the hole portion 42 in the second embodiment describedabove, the configuration of the inspection apparatus is not limitedthereto. For example, as shown in FIG. 10B, the inspection apparatus mayfurther include a displacement sensor 52 that measures the amount ofdisplacement of the main surface S2 of the battery 1 through the holeportion 32. Further, the inspection apparatus may include only thedisplacement sensor 52 of the displacement sensors 51 and 52.

In the case where the inspection apparatus includes the two displacementsensors 51 and 52, the control apparatus 24 is provided with a firstamount of displacement by the displacement sensor 51 and with a secondamount of displacement by the displacement sensor 52. If at least one ofthe first amount of displacement and the second amount of displacementis above a defined value, the control apparatus 24 determines that thebattery 1 is a defective product. In the case where the inspectionapparatus includes the two displacement sensors 51 and 52 in thismanner, the defection detecting accuracy of the battery 1 can be furtherenhanced.

Further, although the displacement sensor 51 measures the amount ofdisplacement of the battery surface under the pressurized state of thechamber 23 in the second embodiment described above, the displacementsensor 51 may measure the amount of displacement of the battery surfaceafter opening the chamber 23.

3 Third Embodiment 3.1 Configuration of Chamber

As shown in FIG. 12A, a third embodiment of the present disclosure isdifferent from the first embodiment in that a chamber 23 according tothe third embodiment of the present disclosure includes a pad portion 61instead of the hole portion 42. The pad portion 61 is one of examples ofthe isolated-space-forming portion that spatially isolates the partialportion of the main surface 51 of the battery 1 within the space portion23 a. The pad portion 61 is communication with the atmosphere outsidethe chamber 23.

The pad portion 61 includes a pad main-body 61 a and a communicationportion 61 b. The pad main-body 61 a has therein a hollow space.Examples of the shape of this space include a semi-spherical shape, acylindrical shape, and a circular truncated conical shape. The padmain-body 61 a is positioned such that a bottom of such a shape isopposed to the main-body portion 31 a of the chamber lower portion 31.It should be noted that the shape of the hollow space is notparticularly limited to those shapes. For the material of the padmain-body 61 a, it is favorable to use a rubber-based material such as anitrile rubber, a fluoro-rubber, a urethane rubber, a silicone rubber,an acrylic rubber, an ethylene-propylene rubber, and a styrene-butadienerubber in view of the adhesion to the main surface S1 of the battery 1.

A side of the hollow space of the pad portion 61, which is opposed tothe main-body portion 31 a of the chamber lower portion 31, is openedand an opposite side thereof is connected to one end of thecommunication portion 61 b. Other end of the communication portion 61 bis pulled out of the chamber 23. Through the communication portion 61 b,the hollow space of the pad main-body 61 a and the atmosphere outsidethe chamber 23 are in communication with each other. The opened side ofthe pad main-body 61 a is pressed and brought into close contact withthe partial portion of the main surface 51 of the battery 1 (e.g.,center portion). In this way, an isolated space that isolates thepartial portion of the main surface 51 of the battery 1 within the spaceportion 23 a is formed. The communication portion 61 b is held at thecenter of the chamber upper portion 41 such that the pad main-body 61 ais movable in a direction closer to or away from the main surface 51 ofthe battery 1.

3.2 Inspection Method

The inspection method for the battery using the chamber 23 having theabove-mentioned configuration further includes a step shown in thefollowing before the pressurization of the chamber 23 (Step S14 in FIG.5) after the lock of the chamber 23 (Step S13 in FIG. 5). Specifically,the inspection method for the battery further includes the followingstep. In this step, in such a manner that the opened side of the padmain-body 61 a is pressed and brought into close contact with thepartial portion of the main surface 51 of the battery 1 (e.g., centerportion), an isolated space that isolates the partial portion of themain surface 51 of the battery 1 within the space portion 23 a isformed. After this step, the compressed gas such as the compressed airis supplied into the chamber 23. A portion of the space portion 23 aother than the isolated space is put in the pressurized atmosphere. Onthe other hand, the isolated space is kept under an atmosphere-openedstate.

3.3 Effect

In the third embodiment, under the pressurized state of the chamber 23,the partial portion of the main surface S1 of the battery 1 can beopened to the atmosphere by the pad portion 61. Thus, the same effectsas those of the first embodiment can be obtained.

3.4 Modified Example

Although the inspection apparatus includes the pad portion 61 instead ofthe hole portion 42 in the third embodiment described above, theconfiguration of the inspection apparatus is not limited thereto. Forexample, as shown in FIG. 12B, the inspection apparatus may furtherinclude a pad portion 62 instead of the hole portion 32.

Hereinabove, although the first to third embodiments of the presentdisclosure have been specifically, the present disclosure is not limitedto the first to third embodiments described above and variousmodifications based on the technical concept of the present disclosuremay be made.

For example, the configurations, the methods, the processes, the shapes,the materials, the numeral values, and the like exemplified in the firstto third embodiments above are merely examples, and differentconfigurations, methods, processes, shapes, materials, numeral values,and the like may be used depending on the needs.

Further, the configurations, the methods, the processes, the shapes, thematerials, the numeral values, and the like of the first to thirdembodiments described above may be combined with one another withoutdeparting from the gist of the present disclosure.

Further, although the inspection apparatus inspects the battery in thefirst to third embodiments described above, the inspection target onlyneeds to have a sealed structure in which the inspection target issealed by the exterior material such as the laminate film, and theinspection target is not limited to the battery. Examples of theinspection target other than the battery include a medical product, asealed product in which an electronic component or the like is sealed,and a sealed product in which a pharmaceutical product, confectionery,or retort food is sealed.

Further, the present disclosure may also take the followingconfigurations.

(1) An inspection apparatus, including:

-   -   a chamber including        -   a space portion configured to house at least a sealed            portion of a battery, and        -   an opening portion configured to open a partial portion of            the battery other than the sealed portion to an atmosphere;            and    -   a pressurizer configured to put the space portion into a        pressurized state.        (2) The inspection apparatus according to (1), in which    -   the opening portion is a hole portion.        (3) The inspection apparatus according to (1), in which    -   the opening portion is an isolated-space-forming portion        configured to spatially isolate the partial portion of the        battery within the space portion, and    -   the isolated-space-forming portion is in communication with the        atmosphere.        (4) The inspection apparatus according to any one of (1) to (3),        further including    -   a measurement unit configured to measure the amount of        displacement of the partial portion of the battery.        (5) The inspection apparatus according to (4), further including    -   a control unit configured to indicate, when the amount of        displacement measured by the measurement unit is above a defined        value, that a sealing failure is caused via an output unit.        (6) The inspection apparatus according to any one of (1) to (5),        in which    -   the battery includes        -   a battery element, and        -   a laminate film with which the battery element is covered.            (7) An inspection method, including:    -   housing at least a sealed portion of a battery in a space        portion of a chamber; and    -   putting the space portion into a pressurized state and opening        the partial portion of the battery other than the sealed portion        to an atmosphere.        (8) A battery-inspecting chamber, including:    -   a space portion configured to house at least a sealed portion of        a battery; and    -   an opening portion configured to open a partial portion of the        battery other than the sealed portion to an atmosphere.        (9) An inspection apparatus, including:    -   a chamber including        -   a space portion configured to house at least a sealed            portion of an inspection target, and        -   an opening portion configured to open a partial portion of            the inspection target other than the sealed portion to an            atmosphere; and    -   a pressurizer configured to put the space portion into a        pressurized state.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present subjectmatter and without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by the appendedclaims.

The invention is claimed as follows:
 1. A method for manufacturing abattery, the method comprising: preparing the battery comprising anexterior material, the exterior material comprising a sealed portion;housing at least the sealed portion of the battery in a space portion ofa chamber; providing the space portion into a pressurized state; andopening a partial portion of the battery other than the sealed portionto an atmosphere.
 2. The method of claim 1 comprising checking swellingdeformation of the partial portion of the battery by using adisplacement sensor.
 3. The method of claim 2 comprising determining asealing failure of the battery based on an amount of the swellingdeformation.
 4. The method of claim 3 comprising comparing the amount ofthe swelling deformation with a predetermined value.
 5. The method ofclaim 1 comprising providing an isolated-space-forming portion tospatially isolate the partial portion of the battery within the spaceportion.
 6. The method of claim 1 comprising providing the chamber in avacuum state.
 7. The method of claim 1 comprising: providing a pressurecontroller connected to a pressurizer and the chamber; adjusting apressure of a gas supplied from the pressurizer into a predeterminedpressure; and supplying the gas into the chamber.
 8. The method of claim1, wherein the battery comprises an electrode, an electrolytic solution,and an electrolyte.